Modular barrier cushion system

ABSTRACT

A modular barrier cushion system is provided for mitigating the impact of a vehicle with a fixed object, and thus, the injury to a driver of the vehicle. The modular barrier system includes a plurality of modular barrier cushions. Each modular barrier cushion includes a cushion body having a shell defining an interior chamber containing shock absorbing or sound absorbing filler material.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. provisional patent application No. 60/228,970 entitled “MODULAR BARRIER CUSHION SYSTEM” filed on Aug. 30, 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Technical Field

[0003] The present invention relates generally to the field of barriers, and more specifically to cushions associated with barriers for mitigating the impact of vehicles, and injury to occupants of such vehicles, with fixed objects, including but not limited to the following: walls, concrete or earthen embankments, metal or wood guard rails, K-rails, Jersey barriers, fencing, light poles and other poles, and the sides of bridges or underpasses.

[0004] 2. Prior Art

[0005] The prior art includes a variety of devices which can be categorized as crash barriers or barricades or lane dividers. Many of these devices and the patents for those devices provide units which are made of concrete such as the “Jersey Barrier” or “K rail”. These can include devices that are made of straight concrete or some sort of lightweight concrete. Others are of a post and beam construction that requires that an upright be inserted into the ground some way and then some wood or metal horizontal members are attached in some fashion. Some have used plain barrels (possibly a 55-gallon size) filled with water or sand. Still others are molded of some sort of polymer and filled with sand or water used as a ballast and/or shock absorber. Alternatively, polymer units have also been filled with polyurethane foam in conjunction with or without some sort of ballast in the bottom of the unit.

[0006] Regardless of the type of construction or the material used in their construction, most of these prior systems share certain characteristics. For example, all or most of these prior devices are designed to be freestanding. Many of the systems have some sort of method for connecting individual unit sections together to form a contiguous and continuous system.

[0007] None of the previous inventions use any type of foam with the exception of polyurethane (PU), and in all of the units which use PU, all can expose the PU to the elements. If moisture is introduced into the PU either from an external source (rain or snow etc.) or from condensation inside the unit, then the unit is exposed to freezing conditions and the inevitable thawing. The PU previously used has been found to lose integrity and can disintegrate.

[0008] The sport of racing has presented particular challenges and needs related to lessening the force of impact of a crash. This need has become more urgent and the search for a solution more frenzied because of recent deaths in this arena. Several methods have been attempted to address the problems. For example, old tires have been stacked along the raceway wall to serve as shock absorbers, but when they are hit they go flying in all directions becoming missiles themselves. Water filled barriers have also been used in the raceway environments, however, the use of water in a barrier can necessitate that the track be dried off before racing can continue if one of these barriers is hit. Sandpits have also been used on some courses along the side of the track to slow a vehicle down, but these usually still require a barrier or cushion to guard the eventual wall that exits the pit.

[0009] Another method attempted to fulfill these needs involves the use of modular barriers and cushions. Plain molded blocks of Expandable PolyStyrene (EPS) have been used loosely placed along the outside and inside walls of racetracks in an attempt to minimize the possible injury to the driver. These blocks are either placed in front of a wall directly, or in front of some other items such as old tires that are placed in front of the wall. One of the objections to these EPS blocks is that when they are struck, pieces can go flying all over the track and can create, as one can imagine, quite a mess which must be cleaned up before the race can continue. Another objection has been that if the block survives for a period of time without being hit, it can yellow because of exposure to the sun. Also, continued exposure to rain and snow can make the EPS blocks waterlogged and might reduce the cushioning properties for which it was intended. Other problems that have surfaced with the EPS blocks is that they are difficult to secure in place, and when one block is hit, 10, 20 or more blocks that are end to end can be moved out of position requiring that all of the blocks be properly repositioned before the race can continue. Moreover, if a car brushes along the foam, it is apt to grab or slow down the car, whereas, if the car scraped along a concrete wall, it would continue with a minimum of impediment. Also, these exposed blocks are subject to dissolving if they come in direct contact with petroleum based products.

[0010] Along a highway or the seashore, there are units that are used for the purposes of sound control and erosion control. With respect to sound control, slabs of concrete have been stacked on top of each other to a height which can absorb or reflect back to the highway the noise produced by passing traffic. These systems can continue for a considerable distance. In some cases the concrete structures are freestanding and in others there are vertical dividers that hold and stabilize the slabs. The slabs have been made with a variety of surfaces, which vary from smooth to those that have some sort of shape cast in the concrete. Moreover, the concrete has been used in its natural color, or in a different color such as sandstone or in some cases even pink for flamingos.

[0011] One of the problems inherent with the use of concrete is the weight of the concrete pieces. Most installations require heavy cranes to install the units. Another problem is the natural checking and cracking that occurs with concrete over time. Yet another concern has been referred to as “thermal upheaval” where the expansion in heat and the contraction in the cold can accelerate the natural cracking process.

[0012] Other systems for sound deadening have included vertical units such as an “I Beam” or pre-stressed concrete post that is inserted in the ground and then some other material such as wood or metal is placed between the verticals. Installations of these types either require a drilling rig to bore a hole fairly deep into the ground into which the vertical is placed, or a pile-driver is used to drive it far enough into the ground.

[0013] Also with this type of system, wood tends to rot over time and ferrous metals tend to rust over time because of the elements and contact with earth. None of these systems are very forgiving if they are crashed into.

BRIEF DESCRIPTION OF THE INVENTION

[0014] The present invention provides a modular barrier system for mitigating the impact of a vehicle with an object and, thus, injury to occupants of the vehicle due to the impact. The modular barrier system includes a plurality of modular barrier cushions. Each modular barrier cushion includes a cushion body having a shell defining an interior chamber containing at least one shock absorbing or sound absorbing filler material. In an exemplary embodiment, the shell is constructed from a resilient material. Each modular cushion includes a cushion body and modular interconnects.

[0015] In one aspect of the invention, the cushion has a first set of modular interconnects and a second set of modular interconnects. In another aspect, the interconnects are a part of the cushion such that the interconnects and cushion are formed from a single shell. A plurality of modular cushions may be interconnected to one another as needed by mating the first set of modular interconnects of a first modular cushion with a second set of modular interconnects of a second modular cushion and securing the modular interconnects with a securing device. Alternatively, the interconnects can be shaped to connect without securing devices. An exemplary interconnect that does not require a securing device is a dovetail interconnect. The modular cushions can be releasably connected to each other and to fixed objects. Additional modular barrier cushions may also be included as necessary. In alternative embodiments, the modular cushions may be connected end to end and/or stacked on top of each other depending on the particular application for which they are being used.

[0016] In another aspect, the present invention provides a crash barrier comprising at least two modular barrier cushions attached to each other via at least one interconnect, each said modular barrier cushion comprising an outer shell casing; and at least one shock absorbing material housed within said shell casing for absorbing the force from impacts.

[0017] Still another aspect of the present invention provides a method for reducing collision damage to a driver of a vehicle comprising the step of: securing at least one modular cushion to an obstacle, said modular cushion comprising an outer shell casing; and at least one shock absorbing material housed within said shell casing for absorbing the force from impacts.

[0018] Another aspect of the invention provides a method for reducing collision damage to a driver of a vehicle comprising the step of securing at least one modular cushion to a fixed object, said modular cushion comprising an outer shell casing, and at least one shock absorbing material housed within said shell casing for absorbing the force from impacts.

[0019] It is an object of the present invention to provide a modular barrier cushion which is adapted to cushion the blow of impact to a driver and or passenger in the event of a crash. While there is always the chance of injury to a driver or passenger in a crash, the device should lessen the force of impact.

[0020] It is a further object of the present invention to provide a modular barrier cushion to mitigate collision damage to objects such as vehicles, fixtures, poles, trees, and the like.

[0021] It is another object of the present invention to provide a device which can be used as a sound-deadening device. An example of this would be along the side of a freeway or other such noisy corridor to deaden the sounds of the vehicles.

[0022] It is yet another object of the present invention to provide a device which can be used as erosion control along a roadway or seashore and as a groin.

[0023] Other objects, aspects, and advantages of the present invention will be apparent to those skilled in the art from a reading of the following detailed disclosure of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024]FIG. 1 is a side elevational view illustrating one embodiment of the modular interconnects of the present invention.

[0025]FIG. 2 is a cross-sectional view of a free standing module embodiment of the present invention.

[0026]FIG. 3 is a side elevational view of the present invention illustrating one embodiment of the present invention having dovetail interconnects.

[0027]FIG. 4 is a top view of another embodiment of the present invention having dovetail interconnects.

[0028]FIG. 5 is a diagram of another embodiment of the present invention in combination with a deadman system.

[0029]FIG. 6 is a side elevational view of the present invention secured within a trench.

[0030]FIG. 7 is a top cross sectional view of one embodiment of the present invention secured around a pole or support.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0031] Referring now to the drawings, the invention will now be described in detail. As shown in FIG. 1, a modular barrier system A is provided for mitigating the impact of a vehicle with a fixed object. Modular barrier system A includes at least a first modular barrier cushion 10 and a second modular barrier cushion 20. Each modular cushion includes a cushion body 14, a first set of modular interconnects 12 and a second set of modular interconnects 22. A plurality of modular cushions can be interconnected to one another as needed by aligning the first set of modular interconnects 12 of a first modular cushion with a second set of modular interconnects 22 of a second modular cushion and securing the modular interconnects with a securing device 30. In one embodiment, the securing device 30 can also secure the modular barrier cushion to the ground 40 or other surface including but not limited to a road, wall, or run way. Additional modular barrier cushions may also be included as necessary. In alternative embodiments, the modular cushions may be connected end to end and/or stacked on top of each other depending on the particular application for which they are being used.

[0032] As shown in the cross-section illustrated in FIG. 2, a free standing embodiment of a modular barrier cushion includes a cushion body 14, which comprises a shell 40 defining an interior chamber 42. In this embodiment, the bottom of the shell is wider than the top to reduce the tendency of the cushion to topple over.

[0033] In an exemplary embodiment, shell 40 is constructed from a resilient material such as, for example and not limitation: Linear Low Density Polyethylene (LLDPE); Low Density Polyethylene (LDPE); High Density Polyethylene (HDPE); High Molecular Weight Polyethylene (HMW); Ultra High Molecular Weight Polyethylene (UHMW); Polypropylene (PP); or Nylon. Regardless of the material used, a UV (Ultra Violet) inhibitor/stabilizer is preferred, but not required, to be present in the resilient material to prevent degradation of the material from exposure to Ultraviolet rays. A suitable UV inhibitor/stabilizer or blocker can be either physical or chemical. Physical barriers will reflect and scatter UV rays away from the cushion and include but are not limited to minerals such as titanium dioxide, zinc ozide and iron oxide. Chemical barriers absorb UV rays and include but are not limited to PABA, cinnimates, benzophenones and dibenzoylmethanes. It is envisioned that shell 40 may be manufactured by a variety of methods, including for example but not limited to: rotational molding; blow molding; vacuum forming; or injection molding.

[0034] The surface characteristics of shell 40 can be varied depending upon the purpose to be served by the modular cushion. For example, in applications such as use in protecting raceway walls the surface could be smooth to allow cars to brush up against the surface without experiencing undue drag or deceleration which might lead to a loss of driver control. In landscaping or noise abatement applications, designs such as bricks, blocks, rocks, trees, birds or any other shape can be molded into the surface of the encasement, either alone or in conjunction with variations in colors. Graphics may be molded into or onto the surface.

[0035] Shell 40 may be constructed in any of a variety of forms or shapes including but not limited to rectangular, triangular, circular, cuboidal, cylindrical, spheriodal, conical, hexagonal, or pyramidal. For example, in some applications wherein the units are intended to be assembled into freestanding stacks, the units could be made thicker to make the stacking more stable. Additionally, progressively higher units could be made to be less thick to further enhance the stacking capabilities. Alternatively, the length and shape of the units could be varied to accommodate curves of varying dimensions.

[0036] In an exemplary embodiment, interior chamber 42 of shell 40 is filled with at least one shock or sound absorbing filler material 44. Materials which have been found to be suitable for use as a filler material 44 include, for example and not limited to: Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam. The density of filler material 44 may range from about one pound per cubic foot up to as much as about 60 pounds per cubic foot depending upon the application for which the modular cushion is intended to be used. The filler material can be a combination of foam and another shock absorbing filler material. The additional shock absorbing material can be another foam, a liquid, or a solid, and can be in the form of beads or particulates and can include: sawdust, solid polymers, plastic or wood chips, sand and the like.

[0037] As illustrated in FIG. 1, individual modular cushions may be interconnected with one another using modular cushion interconnects 12 and 22. It will be appreciated by one of ordinary skill in the art that the interconnects may be part of the cushion such that the interconnects and cushion are formed from a single shell. In such an embodiment, each individual modular cushion is of a shape that enables the cushion to interlock with other modular cushions without additional parts. In one exemplary embodiment, illustrated in FIG. 3, one modular cushion 304 can contain a female dovetail interconnect 308 as part of the unitary shape of the modular cushion, and another modular cushion 302 can have a male dovetail interconnect 306 as part of its unitary shape such that the two may interconnect. In an alternative embodiment, each modular cushion has at least one male and at least one female dovetail interconnect formed from the shell of the modular cushion such that no additional parts are needed to interconnect with another modular cushion.

[0038] In another embodiment, the present invention provides a crash barrier comprising at least two modular barrier cushions attached to each other via at least one interconnect, said modular barrier cushion comprising an outer shell casing; and at least one shock absorbing material housed within said shell casing for absorbing the force from impacts. In one embodiment, the shock absorbing material is a foam material selected from the group consisting of Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam.

[0039] In still another embodiment, modular cushion interconnects 12 and 22 may comprise overlapping rings through which a securing device 30, such as pipe, rod or cylinder may be extended through. Alternatively, interconnects 12 and 22 may include opposed crescents that hook into each other; dovetail interconnects with a male dovetail extending top to bottom on one end that slides into dovetail female on the other end as shown in FIG. 3; and dovetail interconnects with a male dovetail going across the bottom that slide into a dovetail female on the top. In addition to allowing interconnection of individual modular cushions, interconnects 12 and 22 may also be utilized to secure modular cushion units to the ground, a wall, or another barricade or earthen embankment as in FIG. 1.

[0040] Additionally, if more securing is needed, an eyebolt 510 can be attached to the top securing device 30 for attachment to a wall, barricade or embankment via a cable, chain, webbing or other such device. Alternatively, one or more eyebolts 510 can be spaced along the length of securing device 30 to allow attachment to a chain, cable, webbing, or other attachment that will secure the unit to the ground and/or wall, barricade or embankment.

[0041] If the units are used in front of an earthen embankment such as a retention wall or seawall, a “dead-man” system 502 can be used in lieu of or in addition to other methods of securing the units, as in FIG. 5. An exemplary dead-man system can be a rod or T-shaped rod connected to the modular cushion. The dead-man system is covered with backfill such as gravel, dirt, or rock, to provide support for the modular cushion. A plurality of such systems can be used, the number of which can change depending on the size or number of modular cushions used. Other methods known in the art for supporting the modular cushion barrier can also be used.

[0042] Modular cushions may also be held in place as freestanding units in a variety of methods. For example, as illustrated in FIG. 6, a trench 602 may be excavated in the dirt, gravel, rock or other ground surface at a sufficient depth as to sufficiently secure the unit and then to backfill and repack whatever ground material that was excavated. Concrete may also be poured around the unit to secure the unit in place. This can be done with for without the assistance of rebar or other such devices to help anchor the unit into the concrete. Additionally, trenches can be formed that are perpendicular to the line created by the units and poured at the same time to lend more anti-sway stability to the system. Another method would be to form a base from concrete or metal that is already secured sufficiently to the ground. Where the top of this base would be in the shape of a male dovetail that would be received into the bottom of the units.

[0043] The modular cushion system of the present invention is especially well suited for use in raceway applications. In most cases, a system is already in place to prevent a vehicle from leaving the racing surface. These systems are usually involve a substantial concrete wall. In many cases there is something placed in front of the wall as described in the background section. The need exists for a method of lessening the force of impact in a crash against such a wall, and causing a minimum of delay in the race should a device be impacted. The present invention is especially well suited to meet this need.

[0044] The modular cushion system can also be used to minimize collision damage to specific structures. In one embodiment, the modular cushion system of the present invention can surround an object such as a pole 706 including but not limited to a telephone pole, a light pole, a utility pole or the like, or a tree as shown in FIG. 7. Pole 706 can also be a pier or bridge support.

[0045] The modular cushion system can be attached to the object or secured to the ground such that the modular cushion system creates a barrier between the object and an oncoming vehicle. When the vehicle strikes the modular cushion system, the modular cushion system absorbs the energy of the collision thereby reducing the damage to the vehicle, vehicle operator, and the protected object.

[0046] In another embodiment, the modular cushion system can be attached to a vehicle creating a barrier between the vehicle and a colliding object. The colliding object could be another vehicle, a pole, or a tree. The vehicle can be an automobile, motorcycle, water craft, or a non-motorized vehicle. When the vehicle is a water craft including but not limited to boats, canoes, jet skies, and the like, the modular cushion system can be used to prevent the water vehicle from damaging or becoming damaged from contact with a dock mooring platform bridge piling or another vehicle.

[0047] Still another embodiment provides a method for reducing collision damage to a driver of a vehicle comprising the step of securing at least one modular cushion to a fixed object, said modular cushion comprising an outer shell casing; and at least one shock absorbing material housed within said shell casing for absorbing the force from impacts. In one embodiment, the shock absorbing material is a foam material selected from the group consisting of Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam. An obstacle can be walls, concrete or earthen embankments, metal or wood guard rails, Krails, Jersey barriers, fencing, light poles and other poles, sign posts, and the sides and supports of bridges or underpasses.

[0048] The modular cushion system as described above provides at least the following advantages. The modular cushion units can be placed in front of the wall and secured to the wall and/or ground to soften the force of impact and possibly reduce the extent of injury to a driver in case of an accident. Because the unit has a foam core in one embodiment, there is no water that will soak the racing surface and require drying. Because the unit has an encasement around the foam, it should minimize the amount of debris that can be spread on the racing surface and therefore speed up the clean-up process after a wreck. The system of these units can be secured to the ground and/or the wall, an impact to one unit should not cause numerous other units to be displaced or dislodged. This also helps in the speeding up the clean-up process after a wreck.

[0049] Because the units are modular, if a unit should become damaged, the affected unit(s) can be rapidly removed and a new replacement unit installed with a minimum of interruption to the event. In many installations, these spare units can be stored behind the wall that they are cushioning.

[0050] Additionally, because there is a certain amount of flexing properties, which are inherent to polymers, the encasement is not as susceptible to effects of expansion during heat and contraction during cold as other materials might be. Because the foam in these units is encased in a polymer; if the surface of the encasement is fairly smooth, there should be minimum if any “grabbing” or friction that would occur to the vehicle if it simply brushes along the units as compared to if it brushed along units made up of exposed foam or concrete. Furthermore, because the foam in these units is enclosed in a polymer encasement, there is at least some protection from direct contact with petroleum based products which could have an effect on certain types of foam.

[0051] This invention is further described in the attachment hereto which is incorporated by reference herein as if filly set forth. Various modifications may be made to the invention as described without departing from the spirit of the invention or the scope of the appended claims. 

What is claimed is:
 1. A modular barrier cushion comprising: an outer shell casing; at least one shock absorbing material housed within said shell casing for absorbing the force from impacts; and a plurality of interconnects for facilitating interconnection of said modular barrier cushion to additional modular barrier cushions.
 2. The modular barrier cushion of claim 1, wherein the shell is made from a material selected from the group consisting of Linear Low Density Polyethylene (LLDPE); Low Density Polyethylene (LDPE); High Density Polyethylene (HDPE); High Molecular Weight Polyethylene (HMW); Ultra High Molecular Weight Polyethylene (UHMW); Polypropylene (PP); and Nylon.
 3. The modular barrier cushion of claim 1, wherein the shock absorbing material is a foam material selected from the group consisting of Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam.
 4. The modular barrier cushion of claim 1, wherein the interconnects are selected from the group consisting of overlapping rings, opposed crescents that hook into each other, and dovetail interconnects.
 5. The modular barrier cushion of claim 1, wherein the density of shock absorbing material is about 1-60 pounds per cubic foot.
 6. The modular barrier cushion of claim 1, wherein the interconnects and shell are of a single, unitary construction.
 7. The modular barrier cushion of claim 1, wherein the shock absorbing material is in combination with a second shock absorbing material.
 8. The modular barrier cushion of claim 1, wherein a Ultraviolet wavelength inhibitor/stabilizer is present in the shell casing to prevent degradation of the material from exposure to Ultraviolet rays.
 9. The modular barrier cushion of claim 1, wherein the modular barrier cushion is designed to connect to a wall, surface, road, embankment, fixed object or the like.
 10. A crash barrier comprising at least two modular barrier cushions attached to each other via at least one interconnect, each said modular barrier cushion comprising: a) an outer shell casing; and b) at least one shock absorbing material housed within said shell casing for absorbing the force from impacts.
 11. The modular barrier cushion of claim 10, wherein the shell is made from a material selected from the group consisting of Linear Low Density Polyethylene (LLDPE); Low Density Polyethylene (LDPE); High Density Polyethylene (HDPE); High Molecular Weight Polyethylene (HMW); Ultra High Molecular Weight Polyethylene (UHMW); Polypropylene (PP); and Nylon.
 12. The modular barrier cushion of claim 10, wherein the shock absorbing material is a foam material selected from the group consisting of Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam.
 13. The modular barrier cushion of claim 10, wherein the interconnects are selected from the group consisting of overlapping rings, opposed crescents that hook into each other, and dovetail interconnects.
 14. The modular barrier cushion of claim 10, wherein the density of shock absorbing material is about 1-60 pounds per cubic foot.
 15. The modular barrier cushion of claim 10, wherein the interconnects and shell are of a single, unitary construction.
 16. The modular barrier cushion of claim 10, wherein the shock absorbing material is in combination with a second shock absorbing material.
 17. The modular barrier cushion of claim 10, wherein a Ultraviolet wavelength inhibitor/stabilizer is present in the shell casing to prevent degradation of the material from exposure to Ultraviolet rays.
 18. The modular barrier cushion of claim 10, wherein the modular barrier cushion is designed to connect to a wall, surface, road, embankment, fixed object or the like.
 19. A method for reducing collision damage to a driver of a vehicle comprising the step of: securing at least one modular cushion to a fixed object, said modular cushion comprising a) an outer shell casing; and b) at least one shock absorbing material housed within said shell casing for absorbing the force from impacts.
 20. The method of claim 19, wherein the shell is made from a material selected from the group consisting of Linear Low Density Polyethylene (LLDPE); Low Density Polyethylene (LDPE); High Density Polyethylene (HDPE); High Molecular Weight Polyethylene (HMW); Ultra High Molecular Weight Polyethylene (UHMW); Polypropylene (PP); and Nylon.
 21. The method of claim 19, wherein the shock absorbing material is a foam selected from the group consisting of Expandable PolyStyrene (EPS); Polypropylene foam; Polyethylene foam; Polyurethane foam; and Polyester foam.
 22. The method of claim 19, wherein the density of shock absorbing material is about 1-60 pounds per cubic foot.
 23. The method of claim 19, wherein the interconnects and shell are of a single, unitary construction.
 24. The method of claim 19, wherein the shock absorbing material is in combination with a second shock absorbing material.
 25. The modular barrier cushion of claim 19, wherein a Ultraviolet wavelength inhibitor/stabilizer is present in the shell casing to prevent degradation of the material from exposure to Ultraviolet rays. 